Calibration and adjustment determination of surgical handpiece systems

Abstract

A system for calibrating a surgical handpiece system (69) capable of determining a drilling depth of an orthopedic implant kit (230), the system comprising: the surgical handpiece system including a depth measurement extension (134) and configured to determine the thickness of a bone when a drill bit (66) is attached and used to drill through the bone; and a calibration fixture (200) configured to engage with the depth measurement extension of the surgical handpiece system to determine an adjustment amount of the orthopedic implant kit, the calibration fixture comprising a housing (202) defining a receiver configured to receive a surgical screw (232) of the orthopedic implant kit, the housing having a first end configured to approach a distal surface of the surgical handpiece system to axially fix the housing / body of the calibration fixture relative to the surgical handpiece system; and a slider (214) movable within the housing when the screw is engaged.

Description

[0001] Related applications

[0002] This patent application claims priority to and all benefits of U.S. Provisional Patent Application No. 62 / 754,944 filed on November 2, 2018, and Provisional Patent Application No. 62 / 901,878 filed on September 18, 2019, which are incorporated herein by reference in their entirety. Background Art

[0003] Conventional medical and surgical procedures often involve the use of surgical tools and instruments that allow surgeons to access and manipulate surgical sites. As a non-limiting example, rotary instruments such as handheld drills are often used in conjunction with orthopedic surgery to address various musculoskeletal conditions such as trauma, sports injuries, degenerative diseases, joint reconstruction, etc. In procedures employing a handheld drill or similar surgical instrument, a rotational torque selectively generated by an actuator (e.g., an electric motor) is used to rotate a releasably attached drill bit or other surgical accessory at different speeds.

[0004] The surgical handpiece assembly drills a hole in the tissue against which the drill bit is applied. One surgical procedure that necessitates drilling a hole is trauma surgery for repairing a fractured bone. In this type of surgery, an elongated rod (sometimes referred to as a nail) is used to hold the fractured bone parts together. To hold the nail in place, one or more holes are driven into the bone. These holes are positioned to align with complementary holes formed on the nail. A screw is inserted into each aligned hole and the nail hole. The screw holds the nail in place relative to the bone.

[0005] In another type of procedure, an implant called a plate is fixed to the outer surface of each fractured part of the bone to hold the parts together. Screws hold the plate to the individual parts of the bone. In order to attach the screws that hold the plate to the bone, holes for receiving the screws must first be drilled.

[0006] As part of the process for drilling a hole in the bone to receive the screw, it is desirable to know the end-to-end depth of the hole. This information allows the surgeon to select the size of the screw to be installed in the drilled hole. If the screw is too short, the screw may not securely hold the nail inserted into the screw in place. If the screw is too long, the screw may extend beyond the bone an excessive distance. If the screw extends beyond the bone an excessive distance, the exposed end of the screw may rub against the surrounding tissue. If this event occurs, the tissue that the screw rubs against may be affected.

[0007] Therefore, an essential part of many bone hole forming procedures is the measurement of the hole depth. Currently, this measurement is usually performed using a depth gauge that is separate from the drill. This requires the surgeon to insert the depth gauge into the hole after removing the drill bit from the hole. The surgeon then sets the depth gauge based on tactile feedback so that the distal end of the depth gauge extends only to the distal opening of the hole. After these procedures are completed, the surgeon reads the depth gauge to determine the depth of the hole.

[0008] It would be desirable to identify methods and apparatus to improve these devices and methods. Summary of the invention

[0009] The present disclosure generally relates to a system for calibrating a surgical handpiece system capable of determining the drilling depth of an orthopedic implant kit. An exemplary configuration provides a system including a surgical handpiece system. The surgical handpiece system includes a first housing and a depth measurement extension movably coupled to the first housing. A displacement sensor assembly is coupled to the first housing and configured to generate a signal in response to a displacement of the depth measurement extension. A calibration fixture is configured to engage the depth measurement extension of the surgical handpiece system to determine the amount of adjustment of the orthopedic implant kit. The calibration fixture has a second housing defining an inner cavity configured to receive a surgical screw of the orthopedic implant kit. The second housing has a proximal end configured to engage a distal surface of a first housing of the surgical handpiece system to axially constrain the second housing relative to the first housing. A slider is movably coupled to the second housing of the calibration fixture. The slider is configured to move axially relative to the second housing. The slider has a proximal surface configured to engage with the depth measurement extension of the surgical handpiece system. The slider also has a distal surface configured to engage with the surgical screw. The amount of adjustment of the orthopedic implant kit is determined based on the signal from the displacement sensor assembly and the nominal size of the surgical screw.

[0010] Another exemplary configuration provides a system for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopedic implant kit. The system includes a surgical handpiece system. The surgical handpiece system includes a housing and a depth measurement extension movably coupled to the housing. A displacement sensor assembly is coupled to a distal portion of the housing. The displacement sensor assembly is configured to generate a displacement signal in response to movement of the depth measurement extension relative to the housing. A processor is configured to receive a signal from the displacement sensor assembly. A calibration fixture is configured to engage a distal portion of the housing of the surgical handpiece system to engage the depth measurement extension of the surgical handpiece system. One of the surgical handpiece system and the calibration fixture includes a presence sensor and the other of the surgical handpiece system and the calibration fixture includes a transmitter, the presence sensor configured to generate a signal in response to the presence of the transmitter when the calibration fixture engages the distal portion of the housing of the surgical handpiece system. The processor is configured to receive a signal from the presence sensor and determine that the calibration fixture is engaging the distal portion of the housing of the surgical handpiece system and is configured to operate the surgical handpiece system in a calibration mode. The amount of adjustment of the orthopaedic implant kit is determined based on a signal from the displacement sensor assembly while the surgical handpiece system is in a calibration mode and based on a nominal size of the surgical screw.

[0011] Yet another exemplary configuration provides a method for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopaedic implant kit. The method includes providing a surgical handpiece system including a first housing and a depth measurement extension movable relative to the first housing. The method also includes providing a calibration fixture, the calibration fixture including a second housing defining an inner cavity and a slider movable relative to the second housing at least partially within the inner cavity. The method also includes selecting a surgical screw having a specific nominal size from the orthopaedic implant kit. The method also includes selecting a surgical plate to be used in an upcoming operation from the orthopaedic implant kit. The method also includes engaging the depth measurement extension of the surgical handpiece system with the slider of the calibration fixture. The method also includes inserting a surgical screw through the surgical plate to engage the head of the surgical screw so as to abut the surgical plate. The method also includes engaging the slider of the calibration fixture with the surgical screw. The method also includes engaging the distal surface of the second housing with the surgical plate. The method also includes depressing the depth measurement extension of the surgical handpiece system with the slider of the calibration fixture. The method further includes calibrating the surgical handpiece system by determining an adjustment of the orthopaedic implant kit based on a nominal size of the surgical screw and a displacement of the depressed extension.

[0012] Another exemplary configuration provides a method for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopedic implant kit. The method includes providing a calibration fixture and a surgical handpiece system including a displacement sensor assembly. One of the calibration fixture and the surgical handpiece system includes a presence sensor. The other of the calibration fixture and the surgical handpiece system includes a transmitter. The method also includes engaging a distal portion of the surgical handpiece system with a proximal end of the calibration fixture. The method also includes determining, using the presence sensor, that the calibration fixture is engaging a distal portion of the surgical handpiece system. The surgical handpiece system enters a calibration mode in response to the presence sensor detecting the transmitter. The method also includes determining a displacement of a depth measurement extension of the surgical handpiece system in the calibration mode. The method also includes determining an adjustment amount of the orthopedic implant kit in the calibration mode based on the displacement of the depressed depth measurement extension.

[0013] Yet another exemplary configuration provides a system for calibrating a surgical handpiece system capable of determining the drilling depth of an orthopedic implant kit. The system includes the surgical handpiece system. The surgical handpiece system includes a depth measurement extension configured to determine the thickness of a bone when a drill bit is attached and used to drill through the bone. The calibration block is configured to engage with a depth gauge provided with the orthopedic implant kit to determine the amount of adjustment of the orthopedic implant kit. The calibration block includes a top surface having a curved profile, the curved profile being designed to be connected to a plate from the orthopedic implant kit. The top surface defines one or more holes for receiving a depth gauge. The bottom surface of the block includes a recessed portion, the recessed portion being intended to temporarily hold a distal portion of the depth gauge.

[0014] Another exemplary configuration provides a surgical handpiece system for determining an appropriate screw length for bone fixation in conjunction with a bone plate that compensates for an initial screw length value based on the orientation of the surgical handpiece system during drilling. The surgical handpiece system includes a surgical handpiece assembly. The surgical handpiece assembly has a handpiece housing and a motor disposed within the handpiece housing and configured to generate torque. A depth measurement extension is movably coupled to the handpiece housing. A sensor is configured to generate an orientation signal in response to the orientation of the depth measurement extension. The drill bit is configured to be coupled to the motor of the surgical handpiece assembly and receive torque therefrom. A processor is configured to receive a signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a perspective view of a surgical handpiece system including a surgical handpiece assembly and a measurement module, the surgical handpiece assembly shown having a drill bit and a tip protector according to one configuration.

[0016] Figure 2 yes Figure 1A partially exploded perspective view of a surgical handpiece system, wherein the surgical handpiece system is shown having a measurement module, a drive sleeve, and a release assembly spaced apart from a handpiece housing assembly, wherein the end effector assembly is removed from the surgical handpiece assembly and the tip protector is shown spaced apart from the distal cutting tip portion of the drill bit.

[0017] Figure 3 It is along Figure 1 A partial isometric section view taken along line 4-4 in FIG.

[0018] Figure 4 It passes vertically through Figure 1-2 A cross-sectional view of a surgical handpiece assembly with the end effector assembly removed from the surgical handpiece assembly.

[0019] Figure 5 It is a block diagram of some signal processing components of the surgical handpiece system.

[0020] Figure 6 is a cross-sectional view of the distal connection of the calibration fixture to the surgical handpiece system.

[0021] Figure 7 is with Figure 6 The same calibration fixture with all components aligned and compressed.

[0022] Figure 8 is a cross-sectional view taken longitudinally showing a calibration fixture for automatic calibration of a surgical handpiece system.

[0023] Fig. 9 is a perspective view of a calibration fixture used to automatically calibrate a surgical handpiece system prior to calibration.

[0024] Fig.10 is a perspective view of a calibration fixture used to automatically calibrate a surgical handpiece system during calibration.

[0025] Fig.11 is a longitudinal cross-sectional view showing an alternative configuration of a calibration fixture for automatically calibrating a surgical handpiece system.

[0026] Fig.12 is a perspective view of a depth gauge.

[0027] Fig.13 A perspective view of a depth gauge being used to measure the cortex-to-cortex thickness of an artificial bone.

[0028] Fig.14 is a perspective view of the top surface of the calibration block.

[0029] Fig.15 is a perspective view of the bottom surface of the calibration block.

[0030] Fig.16is a perspective view of the surgical board and calibration block.

[0031] Fig.17 A perspective view of the depth gauge, surgical board, and calibration block

[0032] Fig.18 is an enlarged perspective view of the bottom surface of the calibration block and the depth gauge.

[0033] Fig.19 is a front view of a surgical handpiece assembly with a depth measurement extension in a first orientation.

[0034] Fig. 20 is a front view of a surgical handpiece assembly with a depth measurement extension in a second orientation.

[0035] Fig.21A is a cross-sectional view of a drill bit and a depth measurement extension of a surgical handpiece assembly approaching the proximal cortex of a bone.

[0036] Fig.21B is a cross-sectional view of a drill bit and a depth measurement extension of a surgical handpiece assembly resting against the proximal cortex of a bone.

[0037] Fig. 22 is a cross-sectional view of a drill and depth measurement extension of a surgical handpiece assembly resting against the proximal cortex of a bone at an oblique angle relative to the bone.

[0038] Fig.23 is a cross-sectional view of a drill bit and a depth measurement extension of a surgical handpiece assembly with the drill bit penetrating the proximal cortex of a bone at an oblique angle relative to the bone.

[0039] Fig.24 is a cross-sectional view of a drill bit and a depth measurement extension of a surgical handpiece assembly, wherein the drill bit penetrates the proximal cortex and the distal cortex of a bone at an oblique angle relative to the bone.

[0040] Fig.25 is a perspective view of a surgical handpiece system including a surgical handpiece assembly and a remote device.

[0041] Fig.26 is an exemplary flow chart performed by a surgical handpiece system according to the teachings of the present disclosure.

[0042] Fig. 27 is a perspective view of another calibration fixture for automated calibration of a surgical handpiece system.

[0043] Fig.28 yes Fig. 27 Cross-sectional view of the calibration fixture.

[0044] Fig.29 is a perspective view of another calibration block.

[0045] Fig.30 yes Fig.29 Another perspective view of the calibration block.

[0046] Fig.31 yes Fig.29 Cross-sectional view of the calibration block. DETAILED DESCRIPTION

[0047] Referring to the drawings, like reference numerals are used to represent like structures throughout the several views. Figure 1-2 A surgical handpiece system for performing an operating function associated with a medical and / or surgical procedure is shown at 60 in the drawings. In the representative configuration shown herein, the surgical handpiece system 60 is used to facilitate penetration of a patient's tissue, such as bone. To this end, the surgical handpiece system 60 of the illustrated configuration includes a surgical handpiece assembly 62 and an end effector assembly, generally indicated at 64. The end effector assembly 64 in turn includes a drill bit 66 and a tip protector 68. As shown in FIG. Figure 2 As best shown, the drill bit 66 extends generally longitudinally along the axis AX between a cutting tip portion, generally indicated at 70, and an insertion portion, generally indicated at 72. As described in more detail below, the cutting tip portion 70 is configured to engage tissue, and the insertion portion 72 is configured to facilitate releasable attachment of the drill bit 66 to the surgical handpiece assembly 62.

[0048] To help facilitate attachment of drill bit 66 to surgical handpiece assembly 62, in some configurations, tip protector 68 is configured to be releasably secured to cutting tip portion 70 of drill bit 66 while concealing at least a portion of cutting tip portion 70 of drill bit 66, thereby allowing a user of surgical handpiece system 60 (e.g., a surgeon) to safely manipulate and position drill bit 66 during attachment of drill bit 66 to surgical handpiece assembly 62. Once end effector assembly 64 has been attached to surgical handpiece assembly 62, tip protector 68 is subsequently removed from cutting tip portion 70 of drill bit 66, and surgical handpiece system 60 may then be utilized to penetrate tissue.

[0049] Can use multiple different orthopedic (orthopedic) implant kits from different manufacturers, it can comprise screw, plate, nail or pin and depth gauge, each implant kit can comprise the various different screws with the screw length of nominal identification.The depth gauge together with the orthopedic implant kit is configured to measure the drilling depth and provides the user with the measured value corresponding to the nominal screw length in this orthopedic implant kit.The depth gauge has considered following project, such as the thickness of plate and how the manufacturer determines screw length, for example with or without the thickness of screw head.The thickness of bone and the difference between the nominal screw length are called adjustment.

[0050] Reference now Figure 1-4 In the representative configuration shown herein, the surgical handpiece assembly 62 is implemented as a handheld drill having a handpiece housing assembly 74 in the shape of a pistol grip, which is releasably attached to a battery 76 (the battery attachment is not shown in detail). However, it is contemplated that the handpiece housing assembly may have any suitable shape with or without a pistol grip. Although the surgical handpiece assembly 62 shown employs a battery 76 releasably attached to the handpiece housing assembly 74 to provide power to the surgical handpiece assembly 62 for rotating the drill bit 66, it should be understood that the surgical handpiece assembly 62 may be configured in other ways, such as using an internal (e.g., non-removable) battery, or connected to an external console, power source, etc. via a tether. Other configurations are contemplated.

[0051] In the illustrated configuration, a battery 76 or other power source provides power to a controller 78, which in turn is configured to communicate with a user input device 80 and an actuator assembly 82. Both the user input device 80 and the actuator assembly 82 are supported by the handpiece housing assembly 74. The controller 78 is generally configured to facilitate operation of the actuator assembly 82 in response to actuation of the user input device 80. The user input device 80 is shown in the illustrated configuration as a trigger-type configuration, responsive to actuation by a user (e.g., a surgeon), and communicates with the controller 78, for example, via an electrical signal generated by a magnetoresistive sensor (e.g., a Hall effect sensor) and a magnet. Thus, when the surgeon actuates the user input device 80 to operate the surgical handpiece assembly 62, the controller 78 directs power from the battery 76 to the actuator assembly 82, which in turn generates a rotational torque for rotating the drill bit 66 or other surgical end effector, as described in more detail below. Those of ordinary skill in the art will appreciate that the handpiece housing assembly 74, battery 76, controller 78, and user input device 80 may each be configured in a variety of different ways to facilitate generating rotational torque without departing from the scope of the present disclosure.

[0052] Reference now Figure 1-4 The surgical handpiece system 60 of the illustrated configuration also includes a measurement module, generally indicated at 128, which can be optionally configured to be releasably attached to the surgical handpiece assembly 62 to provide measurement functionality to the surgeon during use. To this end, as shown in FIG. Figure 3 and Figure 4As shown, the measurement module 128 generally includes a module housing 130, a guide bushing 132, a depth measurement extension 134, a displacement sensor assembly 136, and a rotatable gear 146. In some configurations, the module housing 130 is releasably attached to the head housing assembly 74. In other configurations, the measurement module 128 is releasably attached to the surgical head assembly 62 in another manner. In certain configurations, the measurement module 128 may include one or more buttons for controlling the functions of the measurement module 128. The module housing 130 generally supports the components of the measurement module 128. In other configurations, the surgical head assembly 62 and the measurement module 128 are non-releasably attached to each other. Instead, the surgical head assembly 62 and the measurement module 128 form an integral assembly such that the module housing 130 forms a part of the head housing assembly 74.

[0053] The depth measurement extension 134 is disposed within the guide bushing 132 and is supported for translation along the measurement axis MX. When the measurement module 128 is attached to the surgical handpiece assembly 62, the measurement axis MX is arranged coaxially with the axis AX. The elongated groove 143 (partially in Figure 2 ) is optionally formed laterally in the depth measurement extension 134 and extends longitudinally.

[0054] The depth measurement extension 134 also includes a plurality of rack teeth 144 arranged linearly along at least a portion of the length of the depth measurement extension 134, the rack teeth being configured to meshingly engage with a gear 146 disposed adjacent the distal end of the guide bushing 132. Figure 4 As shown, the window 142 of the guide bushing 132 is arranged adjacent to the gear 146 to facilitate meshing engagement between the rack teeth 144 and the gear 146, so that the rotation of the gear 146 is proportional to the movement of the depth measurement extension 134. The displacement sensor assembly 136 responds to the rotation of the gear 146 caused by the axial movement of the depth measurement extension 134, and can utilize a potentiometer 147 ( Figure 5), a rotary encoder, etc., so as to generate an electrical signal representing a change in position of the depth measurement extension 134 along the measurement axis MX. Therefore, it will be understood that the displacement sensor assembly 136 can provide enhanced functionality for the surgical handpiece system 60. For example, in some configurations, the displacement sensor assembly 136 can be arranged to communicate with the controller 78, which can be configured to interrupt or adjust how the motor 84 is driven based on the movement of the depth measurement extension 134, such as how to slow down the speed of the drill bit 66 at a specific drilling depth into the tissue. In some configurations, the controller 78 can be set in the measurement module 128. In other configurations, the displacement sensor assembly 136 can be arranged to communicate with a sub-controller (not shown) of the measurement module 128, and the sub-controller can be arranged to communicate with the controller 78. The displacement sensor assembly 136 can also be arranged to communicate with a display 148, such as a display screen, one or more light emitting diodes (LEDs), etc., to provide information related to the movement of the depth measurement extension 134 to the surgeon, such as displaying real-time drilling depth, recorded historical maximum drilling depth, etc. Other configurations can be conceived. This same information can also be transmitted to the user through a speaker to provide an audio indication of real-time drilling depth, recorded historical maximum drilling depth, etc. The disclosure of International Patent Publication No. WO / 2017 / 040783, entitled “Powered Surgical Drill With Integral Depth Gauge That Includes A Probe That Slides Over A Drill Bit” and filed on September 1, 2016, was previously incorporated herein by reference in its entirety.

[0055] The various components of the measurement module 128 can be arranged in a variety of different ways. In addition, while the illustrated measurement module 128 is attached to the illustrated surgical handpiece assembly 62 and is compatible with the calibration fixtures 200, 300, 400, 500, 1300, 1500 of the present disclosure, it is contemplated that the surgical handpiece system 60 may omit the measurement module 128 in some configurations, such as with different types of modules, housings, covers, etc. The measurement module 128 may also be attached to the surgical handpiece assembly 62 at different locations and may be removable or may be a permanent part of the surgical handpiece assembly 62. In configurations where the measurement module 128 is not attached to the distal end of the surgical handpiece assembly 62, components described or depicted herein as abutting the measurement module 128 may alternatively abut the surgical handpiece assembly 62. Further, while the depth measurement extension 134 is shown as a sleeve, it may alternatively partially surround the drill bit 66, or the depth measurement extension 134 may be parallel to the drill bit 66 and offset therefrom. In other words, any device that includes the depth measurement extension 134 may be compatible with the devices and methods described herein.

[0056] Figure 5 Depicted are the basic electrical components of the surgical handpiece system 60 that provide an indication of the depth of the hole formed by the drill bit 66 based on the position of the depth measurement extension 134. The voltage adjustment components that ensure that the drive signal of the appropriate potential is provided to the drilling depth display component are not identified. The components that provide information about the drilling depth include a potentiometer 147. A voltage is applied to one end of the potentiometer 147. The opposite end of the potentiometer 147 is grounded. The voltage present on the tap of the potentiometer 147 is applied to the processor 236. Also shown attached to the processor 236 is a zeroing switch 150. In the zeroing switch 150, a display 148 can be mounted.

[0057] Each plate 234 screw 232 kit may provide a nominal screw length to identify the various screw sizes within the kit. The nominal screw length provided for any particular plate 234 screw 232 kit does not necessarily correspond to any consistent measurement. The nominal screw length may be the actual screw length with or without the screw head. The nominal screw length may or may not take into account the thickness of the plate 234 with which the screw will ultimately be used. To ensure that the surgeon properly selects the screw 232 appropriate for a particular surgical procedure, a manufacturer-specific depth gauge 260 is provided with each plate 234 screw 232 kit (see, e.g., Fig.12 ).

[0058] like Fig.13 As shown, the depth gauge 260 is used to measure the thickness of bone 266, and the measurement markings 262 on the depth gauge 260 associated with a given kit correspond to the nominal screw length of the screws 232 provided for that kit.

[0059] In order for the surgical handpiece system 60 to provide sufficient information to enable the selection of screws 232, the surgical handpiece system 60 must be calibrated to work with any of the more than 1300 different sets of plates 234 screws 232. As described below, the surgical handpiece system 60 can be calibrated using the plates 234 screws 232 provided with a particular implant kit 230 or the depth gauge 260 provided with the implant kit 230.

[0060] exist Figure 6 and 7 , a system for calibrating a surgical handpiece system 60 is shown in . In this system, screws 232 and plates 234 from the kit are used in conjunction with the measurement module 128 and the calibration fixture 200 to calibrate the measurement module 128 of the surgical handpiece system 60.

[0061] In this system, a calibration fixture 200 has an elongated housing 202, such as a tubular or rectangular housing, having a proximal opening 204 at a proximal end 206 and a distal opening 208 at a distal end 210. The housing 202 defines an interior cavity 212.

[0062] The housing 202 includes a slider 214 that is freely movable axially within the lumen 212 of the housing 202. A proximal surface 226 of the slider 214 is designed to abut against the distal end 138 of the depth measurement extension 134 of the measurement module 128. A distal surface 228 of the slider 214 is designed to engage the tip of a selected screw 232.

[0063] To use Figure 6 and 7 In the system of FIG. 1 , the depth measurement extension 134 can be fully extended from the measurement module 128. The housing 202 is sleeved on the depth measurement extension 134 so that the depth measurement extension 134 is arranged in the inner cavity 212. In addition, the proximal end 206 of the housing 202 is pressed against the end of the measurement module 128, or can be fixed to the measurement module 128 using an interlocking mechanism 216. Although the interlocking mechanism is shown here as an interlocking recess 218 and a protrusion 220, it should be understood that the interlocking mechanism can also take other suitable forms.

[0064] The slider 214 of the calibration fixture 200 is located at the distal region of the calibration fixture 200 and abuts the extended depth measurement extension 134, which is referred to as the starting point SP. The slider 214 is configured to move axially within the inner cavity 212 of the housing 202. The precise movement of the slider 214 can be guided by the wing 222 that can be placed in the groove 224 of corresponding size in the housing 202 to ensure smooth movement relative to the longitudinal axis of the inner cavity. The slider 214 can alternatively interact with the housing 202 in other ways to ensure smooth movement within the inner cavity 212 of the housing 202.

[0065] The user actuates one or more user inputs on the measurement module 128 or surgical handpiece assembly 62 to operate the measurement module 128 in the calibration mode. This zeroes the measurement module 128. The user then selects a screw 232 and a plate 234 of any length from the kit to be used. The plate 234 is placed against the distal end 210 of the calibration housing 202, and the screw 232 is inserted through the distal opening 208 of the plate 234 into the distal end 210 of the calibration fixture 200. The end of the screw 232 displaces the slider 214 and the depth measurement extension 134 so that the slider 214 stops at the final position FP, as shown in FIG. Figure 7 The display 148 of the measurement module 128 can display the resulting displacement of the measured extension.

[0066] exist Figure 6 and7 In the example of , the user selected a 26 mm screw, which displaced the depth measurement extension 134 by 23 mm. This displacement correlates to the cortex-to-cortex bone thickness as measured by the surgical handpiece system 60. The difference (3 mm) between the marked length of the selected screw 232 (26 mm) and the measured displacement (23 mm) is the length adjustment for this particular screw 232 and plate 234 set. The user can then enter a "calibration mode," which allows the length adjustment to be entered into the measurement module 128 and stored in the memory unit of the measurement module 128 for use throughout the remainder of the surgical case.

[0067] The user can then enter "drill mode" by actuating one or more user inputs on the surgical handpiece system 60. While in drill mode, as the user drills through the patient's bone, the stored adjustment value will be automatically added to the real-time depth measurement and the measured cortex-to-cortex value determined by the measurement module 128. For a given system, this technology effectively bridges the gap between the absolute measurement of bone thickness and the correct screw selection. Alternatively, the user can retain the adjustment value to achieve the appropriate screw 232 selection. In other words, when determining the appropriate screw length to use, the user will know that he or she needs to add 3mm to the measurement determined by the measurement module 128.

[0068] Figure 8 , 9 10 shows another calibration system using a surgical handpiece system 60, wherein the measurement module 128 is connected to an alternative design of a calibration fixture 300, wherein screws 232 and plates 234 from a kit are used to calibrate the surgical handpiece system 60. Figure 6 and 7 The systems and methods shown have been subjected to some modifications and additions.

[0069] The calibration fixture 300 is shown having a T-shaped housing 302. The T-shaped housing 302 provides ergonomic benefits when holding the calibration fixture 300. The T-shape also provides a larger surface area for the plate 234 to rest against.

[0070] The surgical handpiece system 60 and the calibration fixture 300 may include a calibration sensor assembly 340. A sensor 342 is included in the measurement module 128. The sensor 342 may be coupled to a processor within the measurement module 128 or the surgical handpiece assembly 62. The processor 236 is configured to determine whether the calibration fixture 300 is positioned near the surgical handpiece system 60 based on an input signal from the sensor 342. The sensor assembly 340 may include a second component, such as a transmitter, which is located in the calibration fixture 300 and is configured to transmit a signal to the sensor 342. When the processor 236 determines that the calibration fixture 300 is located near the measurement module 128, the processor may cause the measurement module 128 to automatically enter a calibration mode. It should be understood that the processor may be adjusted so that the processor determines that the calibration fixture 300 is close only when the distance between the calibration fixture 300 and the measurement module 128 is less than a predetermined distance (e.g., less than 1 mm). In other configurations, the processor may be adjusted so that the processor only determines that the calibration fixture 300 is abutting the measurement module 128. In other configurations, the processor may cause the measurement module 128 to automatically enter the calibration mode when the measurement module 128 first receives power from the surgical handpiece assembly 62 or another portion of the surgical handpiece system 60.

[0071] In one possible embodiment, the sensor 342 comprises a magnetoresistive sensor. The sensor 342 may be positioned near the distal end of the measurement module 128 or the surgical handpiece assembly 62. The calibration fixture 300 may include a transmitter 346, such as a magnet, positioned near the proximal end 306 of the calibration fixture 300. It is contemplated that the sensor assembly 340 may take other suitable forms to detect proximity to the calibration fixture 300, for example, the sensor 342 may take the form of a mechanical button or switch that is pressed, an RFID antenna that is triggered by a coil included on the calibration fixture 300, a capacitive sensor, or a Hall effect sensor.

[0072] It is also contemplated that a plurality of transmitters 346 may be arranged near the proximal end of the calibration fixture 300 to allow the sensor 342 to detect one or more of the plurality of transmitters 346 when the calibration fixture 300 is proximate to the measurement module. This feature is advantageous because the calibration fixture 300 may be positioned radially at a plurality of different positions relative to the measurement module 128, and the sensor 342 may still determine that the calibration fixture 300 is proximate to the measurement module 128. In one configuration, the transmitter array 346 may be arranged around a proximal opening of the calibration fixture 300 that is configured to receive the depth measurement extension 134. The transmitter array 346 may be circumferentially spaced such that the sensor 342 may detect that the calibration fixture is proximate relative to the measurement module 128 in any radial direction of the calibration fixture 300.

[0073] In other configurations, the sensor 342 may be coupled to the calibration fixture 300 near the proximal end of the calibration fixture 300 , and the transmitter 346 may be coupled to the measurement module 128 near the distal end of the module housing 130 .

[0074] Once the processor determines that the calibration fixture 300 is positioned near the surgical handpiece system 60 based on the input signal from the sensor 342, the processor can cause the measurement module 128 or the surgical handpiece assembly 62 to enter a calibration mode. Figure 6 and 7 During the process described by the system shown in FIG. 1 , the measurement module 128 determines the length adjustment for a given set of screws 232 for a plate 234, and the measurement module 128 stores the length adjustment in the memory unit of the measurement module 128, and the user re-enters the drilling mode. In the drilling mode, the length adjustment can be automatically added to the measured displacement to inform the surgeon of the correct screw selection.

[0075] It should also be understood that when the processor 236 determines that the calibration fixture 300 is no longer in the vicinity of the surgical handpiece system 60, the processor 236 can also send a command to the measurement module 128 to automatically enter the drilling mode of the measurement module 128. This feature can be further based on the amount of time that has passed. For example, 15 seconds after the processor 236 determines that the calibration fixture 300 is no longer close to the head, the processor 236 can cause the measurement module 128 to re-enter the drilling mode. It should be understood that although the entire description refers to the measurement module 128 performing logical steps, those same logical steps can be performed by any component of the surgical handpiece assembly 62. These steps include, but are not limited to, performing calculations, determining proximity, and entering calibration or drilling mode.

[0076] exist Figure 8-10 In the system of FIG. 2 , the calibration housing 302 is fitted over the depth measurement extension 134, or it is pressed against the distal end of the surgical handpiece system 60, or it can be secured to the surgical handpiece system 60 using an interlocking mechanism (not shown). Prior to inserting the screw 232, the slider 314 of the calibration fixture 300 can be placed at a distal region of the lumen 312 of the calibration fixture 300. The distal end of the depth measurement extension 134 abuts the proximal end 336 of the slider 314. As described above, when the processor 236 detects that the calibration fixture 300 is positioned proximal to the surgical handpiece system 60, the measurement module 128 can automatically enter the calibration mode.

[0077] When the measurement module 128 enters calibration mode, the depth reading is zero and the processor 236 awaits further input from the displacement sensor assembly 136 associated with the depth measurement extension 134. The user is then prompted on the display 148 to select a screw 232 from the kit having a specific nominal screw length, for example 26 mm. The ideal screw length is between 24 and 36 mm because this length is typically included in each type of implant kit for smaller bones (such as those in the foot) and in each implant kit for larger bones (such as the femur). The bone abutment surface 238 of the plate 234 is placed against the distal end of the calibration fixture housing 302, and the screw 232 is inserted through the plate 234 into the distal end of the calibration fixture 300. The end of the screw 232 contacts the distal end 338 of the slider 314, which displaces the slider 314 and the depth measurement extension 134, as shown in FIG. Figure 8 and 10 shown.

[0078] In other configurations where the calibration mode has been entered via a user input device, the screw 232, plate 234, and calibration housing 302 may be engaged with one another prior to placing the calibration fixture 300 proximate the measurement module 128, by coupling the measurement module 128 to the surgical handpiece assembly 62, or by another means. The bone abutment surface 238 of the plate 234 is placed against the distal end of the calibration fixture housing 302, and the screw 232 is inserted through the plate 234 into the distal end of the calibration fixture 300. The end of the screw 232 contacts the distal end 338 of the slider 314. The calibration fixture 300 is then placed proximate the measurement module 128 and the slider 314 displaces the depth measurement extension 134. It is contemplated that the calibration fixture 300, measurement module 128, screw 232, and plate 234 may be engaged with one another in a different order and accurate adjustment may be properly provided as long as the relative positions and engagements remain the same as shown in the configuration shown and described herein.

[0079] In other configurations, the user may be directed to insert one of a plurality of screws having a predetermined nominal length. The measurement module 128 may detect that the screw 232 has a particular nominal length based on a range within which the displacement of the depth measurement extension falls, and the measurement module 128 may then determine an adjustment based on the displacement of the depth measurement extension 134 and the identified nominal screw length. For example, the user may be prompted on the display 148 to select a screw 232 having a first nominal screw length of the kit or having a second nominal screw length of the kit. The measurement module 128 may automatically determine which screw is selected based on the displacement of the depth measurement extension 134 and the range within which the displacement falls. After the measurement module 128 determines which screw is selected, the adjustment amount may be determined as described herein.

[0080] In some configurations, one or more adjustment parameters must be satisfied in order for the measurement module 128 to record the final displacement of the depth measurement extension 134 to determine the adjustment amount. One adjustment parameter may be that the sensor 342 determines that the calibration fixture 300 is close to the measurement module 128 to establish an accurate tolerance stack between the calibration fixture 300 and the measurement module 128. Another adjustment parameter may be that the relative position of the depth measurement extension 134 relative to the module housing 130 is within a certain range. For example, if the user selects a screw 232 from the kit that is too short so that the slider 314 and / or the depth measurement extension 134 cannot be moved to a certain minimum threshold, the displacement may not be recorded, and the user may need to use a longer screw 232. Similarly, if the user selects a screw 232 from the kit that is too long, so that the slider has been displaced to the maximum threshold, the displacement may not be recorded, and the user may need to use a shorter screw 232. Additionally, if the screw 232 is too long, the head of the screw may not abut the plate 234 if the slider 314 is at the proximal end of the lumen 312 and the screw 232 is longer than the distance between the distal end of the slider 314 and the distal end of the calibration housing 302. Yet another adjustment parameter may be that the position of the depth measurement extension 134 relative to the calibration housing 302 remains constant for a particular duration. For example, the user may be required to hold the calibration housing 302 steady for a minimum amount of time, e.g., 0.2 to 3 seconds, in order for the measurement module 128 to record the resulting displacement from the selected screw.

[0081] The measurement module 128 automatically calculates and stores the length adjustment. This calculation is possible because it is Figure 8 Dimension A is the mechanical superposition of the known and measured distances specified in , thus. Dimension A is the length of the calibration fixture 300 from the proximal end 306 to the distal end 310, and is also the space between the distal end of the measurement module 128 and the bone abutment surface 238 of the plate 234. Dimension B is the distance from the distal end of the measurement module 128 to the distal end of the depth measurement extension 134, which is measured using the measurement module 128. Dimension C is the length of the slider 314. Finally, dimension D is the unknown distance from the tip of the selected screw to the bone abutment surface 238 of the plate 234.

[0082] The measurement module 128 can simply subtract dimension B and dimension C from dimension A to determine dimension D, the displacement caused by the insertion of the screw 232. If the screw 232 is inserted into the bone, rather than into the calibration fixture 300, dimension D is related to the cortex-to-cortex bone thickness. Since the nominal length of the screw 232 is also known, the measurement module 128 can determine the adjustment by subtracting dimension D from the nominal screw length, and automatically save the length adjustment to the memory unit during the ongoing process of the surgical case. Alternatively (or additionally), the adjustment can be reported to the user using the display 148 or the speaker or both. The adjustment can be rounded. For example, since the kit of screws 232 is provided in increments of 1 or 2 mm, the measurement module 128 can round the output recommended screw length to the nearest mm, or automatically round up or down to the next mm or the next even mm.

[0083] Certain applications may benefit from ensuring that the screw is long enough to fully penetrate the bone, so in these cases, rounding up may be preferable. In other operations, the risk of a protruding screw tip damaging surrounding tissue is greater, and rounding down may be preferable. The surgical handpiece system 60 can receive information about the planned procedure and modify its calculation of the recommended screw length accordingly.

[0084] In the exemplary calculation, based on Figure 8 The system shown can instruct the user to insert a screw 232 with a nominal length of 30 mm. This can produce a dimension D of 28 mm. The adjustment is 2 mm (i.e., the difference between the D dimension of the 28 mm displacement and the nominal value of 30 mm). The 2 mm adjustment is stored. Then, after drilling is completed, if it is determined that the cortex-to-cortex bone measurement is 34 mm, the measurement module 128 will output a recommended screw length of 36 mm.

[0085] The calculation being performed by a processor rather than manually further improves the accuracy of the adjustment because it allows additional significant figures to be included in the adjustment.

[0086] Reference Fig. 27 and 28 , showing an alternative configuration of the calibration fixture 1300. It should be understood that various configurations of the calibration fixture 1300 may include Figure 8-10 Those similar elements shown may be identified by reference numerals increased by 1000. It should be understood that those elements including reference numerals increased by 1000 may have the same features as described above.

[0087] Fig. 27 and 28Another calibration system is shown that uses a surgical handpiece system 60 connected to another design 1300 of a calibration fixture using a measurement module 128, wherein screws 232 and plates 234 from a kit are used to calibrate the surgical handpiece system 60.

[0088] Similar to Figure 8-10 300, the calibration fixture 1300 is shown as having a T-shaped housing 1302. The T-shaped housing 1302 provides ergonomic benefits when holding the calibration fixture 1300. The T-shape also provides a larger surface area for the plate 234 to rest against.

[0089] and Figure 8-10 Another similarity of the calibration fixture 300 shown in FIG. 1 is a calibration sensor assembly (not shown). Sensor 342 is coupled to a processor within the measurement module 128 or the surgical handpiece assembly 62. The processor 236 is configured to determine whether the calibration fixture 1300 is positioned near the surgical handpiece system 60 based on an input signal from the sensor 342. The sensor assembly may include a second component disposed in the calibration fixture 1300 and configured to transmit a signal to the sensor 342. When the processor 236 determines that the calibration fixture 1300 is positioned near the measurement module 128, the processor causes the measurement module 128 to automatically enter a calibration mode. It should be understood that the processor may be adjusted so that the processor determines that the calibration fixture 1300 is nearby only when the distance between the calibration fixture 1300 and the measurement module 128 is less than a predetermined distance, such as less than 1 mm.

[0090] In one possible embodiment, sensor 342 includes a magnetoresistive sensor (e.g., a Hall effect sensor). Sensor 342 may be positioned near the distal end of measurement module 128 or surgical handpiece assembly 62. Calibration fixture 1300 may include a magnet 1346 positioned near proximal end 1306 of calibration fixture 1300. It is contemplated that sensor assembly 340 may take other suitable forms to detect proximity of calibration fixture 1300, for example, sensor 342 may take the form of a mechanical button or switch that is pressed, an RFID antenna that is triggered by a coil included on calibration fixture 1300, or a capacitive sensor.

[0091] Once the processor determines that the calibration fixture 1300 is positioned near the surgical handpiece system 60 based on the input signal from the sensor 342, the processor causes the measurement module 128 or the surgical handpiece assembly 62 to enter a calibration mode. Figure 6 and 7For the system shown in FIG. 1 , the user re-enters drilling mode by determining the length adjustment for a given set of plates 234 screws 232 throughout the described process, and the measurement module 128 stores the length adjustment in the memory unit of the measurement module 128. In drilling mode, this length adjustment can be automatically added to the measured displacement to inform the surgeon of the correct screw selection.

[0092] It should also be understood that when the processor 236 determines that the calibration fixture 1300 is no longer in the vicinity of the surgical handpiece system 60, the processor 236 may also send a command to the measurement module 128 to automatically enter the drilling mode. This feature may be further based on the amount of time that has passed. For example, the processor 236 may cause the measurement module 128 to re-enter the drilling mode 15 seconds after the processor 236 determines that the calibration fixture 1300 is no longer in proximity to the handpiece. It should be understood that although the entire specification refers to the measurement module 128 performing logical steps, those same logical steps may be performed by any component of the surgical handpiece assembly 62. These steps include, but are not limited to, performing calculations, determining proximity, and entering calibration or drilling mode.

[0093] The calibration fixture housing 1302 can be fitted over the depth measurement extension 134 and can be pressed against the distal end of the surgical handpiece system 60, or can be secured to the surgical handpiece system 60 using an interlocking mechanism (not shown). Prior to inserting the screw 232, the slider 1314 of the calibration fixture 1300 is placed at the distal region of the inner cavity 1312 of the calibration fixture 1300. The distal end of the depth measurement extension 134 abuts the proximal end 1336 of the slider 1314. As described above, when the processor 236 detects that the calibration fixture 1300 is located near the surgical handpiece system 60, the measurement module 128 can automatically enter the calibration mode. When the measurement module 128 enters the calibration mode, the depth reading is zero, and the processor 236 waits for further input from the displacement sensor assembly 136 associated with the depth measurement extension 134. The user is then prompted on the display 148 to select a screw 232 having a specific nominal screw length from the kit. The bone abutment surface 238 of the plate 234 is placed against the distal end of the calibration fixture housing 1302, and the screw 232 is inserted through the plate 234 into the distal end of the calibration fixture 1300. The end of the screw 232 contacts the distal end 1338 of the slider 1314, which displaces the slider 1314 and the depth measurement extension 134.

[0094] The distal end of the calibration housing 1302 has a distal surface that may include a ridge 1348 designed to have a curvature similar to that of bone and thereby closely engage the bone abutment surface 238 of the plate 234. The ridge 1348 is an optional modification of the calibration housing 1302. Instead of a ridge, the entire distal surface of the calibration housing 1302 may be curved or flat.

[0095] The slider 1314 may include a biasing mechanism 1350 configured to abut the side wall of the calibration housing 1302 defining the inner cavity 1312 of the calibration housing 1302. The biasing mechanism prevents the slider 1314 from freely moving in the inner cavity 1312 of the calibration housing. It should be understood that, despite the constraint on the free movement of the slider 1314, the slider 1314 can still be moved via user manipulation as described above. The biasing mechanism 1350 may include a spring-loaded plunger. It is conceivable that other biasing mechanisms may be used to abut the side wall of the calibration housing 1302 to prevent other free movement of the slider 1314 in the inner cavity 1312 of the calibration housing 1302. The spring-loaded plunger may include a body and a ball (or in some cases a pin) at least partially received in a recess of the body. The ball is movably connected to the body to protrude outward from the body toward the side wall of the calibration housing 1302. The spring positioned within the recess of the body is configured to apply a constant force to the ball to bias the ball toward the sidewall of the calibration housing 1302. The engagement of the ball against the sidewall of the calibration housing 1302 serves to prevent the slider 1314 from freely moving within the inner cavity 1312.

[0096] Fig.11 Another alternative housing for the above automatic calibration is disclosed. Figure 8-10 ) and T-shaped housing 1302 ( Figure 27-28 ), the housing 402 is used. The depth measurement extension 134 is still inserted into the first receiver 448 on the housing 402. The screw 232 is inserted into the plate 234, and the kit is inserted into the second receiver 450 on the housing 402. The screw head is fixed in place with a centering spring 452. The second receiver 450 is open along the proximal end 406 of the calibration fixture 400 and along the side 454. Once the screw 232 is inserted through the plate 234, both can be placed in the second receiver 450 through the side opening 454 of the calibration fixture 400. Finally, a dimple 456 can be added to the distal end of the surgical head assembly 62 or the measurement module 128 to better fix the tip of the screw 232 to prevent movement during calibration.

[0097] In this configuration, since the displacement of the depth measurement extension 134 is known and the position of the proximal end of the plate relative to the distal end of the depth measurement extension 134 is known, the measurement module 128 can more directly calculate dimension D, the distance from the proximal end of the plate to the distal end of the measurement module 128. In other words, dimension E (the known distance from the distal end of the depth measurement extension 134 to the bone abutment surface 238 of the plate 234) can be subtracted from dimension F (the known distance from the distal end of the depth measurement extension 134 to the pocket 456) to determine dimension D. Again, since the nominal length of the selected screw 232 is known, the adjustment amount can be determined by subtracting dimension D from the nominal length of the screw 232 and the adjustment amount can be automatically saved for the duration of the surgical case. In an alternative form, the adjustment amount can be reported to the user.

[0098] Figure 14-18 A system is depicted that can be used to determine the amount of adjustment of a screw 232 and plate 234 assembly. The system relies on the depth gauge 260 ( Fig.12 and 13 ) and the plate 234 in the kit to be used, and the calibration block 500 to determine the adjustment amount. The calibration block 500 is elongated with rounded edges. The illustrated calibration block 500 is designed to fit easily into one hand, but can have several shapes, including T-shaped or square corners and edges. In addition, the calibration block 500 has a top surface 502, which includes a ridge 504, which is designed to have a curvature similar to that of a bone and thus tightly engages the bone abutment surface 238 of the plate 234. The ridge 504 is an optional improvement of the calibration block 1500. Instead of the ridge, the entire top surface 502 of the calibration block 500 can be curved or flat. In addition, the calibration block 500 includes two holes, a smaller hole 506 and a larger hole 508. The calibration block 500 may include only one hole or more than two holes. The different sizes of the smaller hole 506 and the larger hole 508 are to provide a fit with the depth gauge 260 provided in the screw 232 plate 234 kit. Each of the smaller hole 506 and the larger hole 508 has a known depth. Figures 14 to 18In the embodiment of the present invention, two holes 506 / 508 have a depth of 30 mm. Alternative designs with different depths can be used. For example, for bones of the hands and feet, it may be useful to provide a shorter depth for the smaller holes for use with the depth gauge 260 provided with the screw 232 and plate 234 kit. The larger holes can have a longer depth, giving the calibration block 500 a more triangular shape along its side profile. The holes of the calibration block 500 can also be marked with the hole depth. Around each of the smaller and larger holes 506, 508, the bottom surface 510 includes a raised edge 512 within a receiver 514. The raised edge 512 and the receiver 514 respectively provide an improved surface for stabilizing the hook of the depth gauge 260, but they are also optional.

[0099] Determining the amount of adjustment of the orthopedic screw 232 and plate 234 assembly using the calibration block can be accomplished as follows: Figure 16-18 , the plate 234 is placed over the appropriate hole, in this example the smaller hole 506 is used. The selected plate 234 should be placed on the calibration block 500 in the same manner as it is placed on the bone during implantation. The bone abutment surface 238 should be placed so that it contacts the top surface 502 of the calibration block 500. The depth gauge 260 is then inserted into the smaller hole 506. The hooked end 264 of the depth gauge 260 rests on the bottom surface 510 of the calibration block 500. The user then obtains the screw length from the measurement markings 262 of the depth gauge 260.

[0100] In this example, Fig.17 The nominal screw length is 33 mm on the depth gauge 260. Therefore, the adjustment is 33 mm - 30 mm hole depth or 3 mm. The user can retain the 3 mm adjustment and add the adjustment to the output of the measurement module 128 after drilling. Alternatively, the user can provide the adjustment to the surgical handpiece system 60 so that the recommended screw length output is automatically based on the manufacturer's nominal screw length. Prior to each case, the user can be instructed to provide the adjustment through the display 148 of the surgical handpiece system 60. The memory of the surgical handpiece system 60 will then store the adjustment for the entire duration of the surgical case.

[0101] Reference Figure 29-31 , showing an alternative configuration of the calibration block 1500. It should be understood that various configurations of the calibration block 1500 may include Figure 14-18 Similar elements to those shown in , may be identified by reference numerals increased by 1000. It should be understood that those elements including reference numerals increased by 1000 may have the same features as described above.

[0102] Figure 29-31A system is depicted that can be used to determine the amount of adjustment of a screw 232 and plate 234 assembly. The system relies on the depth gauge 260 ( Fig.12 and 13 ) and the plate 234 in the kit to be used, and the calibration block 1500 to determine the adjustment amount. The calibration block 1500 is elongated and has rounded edges. The illustrated calibration block 1500 is designed to be easily placed in one hand, but can have several shapes, including T-shaped or square corners and edges. In addition, the calibration block 1500 includes contoured sides to help the user grasp the calibration block 1500. In addition, the calibration block 1500 has a top surface 1502, which includes a ridge 1504, which is designed to have a curvature similar to that of a bone, so that it tightly engages the bone abutment surface 238 of the plate 234. The ridge 1504 is an optional improvement of the calibration block 1500. Without the ridge, the entire top surface 1502 of the calibration block 1500 can be curved or flat. In addition, the calibration block 1500 includes a hole 1506. The calibration block 1500 can include more than one hole. The hole 1506 has a known depth.

[0103] Determining the amount of adjustment of the orthopaedic screw 232 and plate 234 set using the calibration block 1500 can be accomplished in the following manner: Place the plate 234 over the hole 1506. The selected plate 234 should be placed on the calibration block 1500 in the same manner as it is placed on the bone during implantation. The bone abutment surface 238 should be placed so that it contacts the top surface 1502 of the calibration block 1500. The depth gauge 260 is then inserted into the hole 1506. The hooked end 264 of the depth gauge 260 rests against the bottom surface 1510 of the calibration block 1500. The user then obtains the screw length from the measurement markings 262 of the depth gauge 260.

[0104] The calibration block 1500 may define a cavity 1516 to reduce the weight of the calibration block 1500. The cavity 1516 being open at both ends advantageously allows for easier cleaning of the cavity. However, it is contemplated that the cavity 1516 may alternatively be closed at one end such that the cavity creates a blind hole.

[0105] In certain surgical procedures, it may be necessary to insert the screw 232 or other implant into the patient's bone at an oblique angle. In such procedures, the proper selection of the screw length for the procedure may require further compensation of the nominal screw length. In some procedures, when inserted at an oblique angle, the head of the screw 232 may not fully seat into the bevel on the proximal side of the bone plate 234 or be completely parallel to the outer surface of the proximal cortex 550 of the patient's bone (see FIG. Figures 21A-24). For example, in a process where drilling through the proximal and distal cortices is required, when the screw is inserted at an oblique angle, the portion of the plate 234 that the head of the screw 232 abuts may be different from the portion that the head of the screw abuts when the screw is orthogonal to the hole of the plate, which may prevent the screw 232 from being fully seated in the plate hole. If the head of the screw 232 is not fully seated in the plate hole and compensation is not performed, the selected screw length output by the measurement head may be shorter than required, and the screw 232 may not pass through or insert the distal cortex 552 during operation. By adding the compensation length based on the angle at which the screw 232 is inserted, the possibility of the screw 232 being too short is reduced. For various combinations of plates 234 screws 232 as described above, the compensation length can be in addition to the adjustment amount length provided by the calibration of the surgical handpiece system 60. In other words, the appropriate screw length can be selected by calibrating the surgical handpiece system 60 for the specific screw 232 type and plate 234 selected and by compensating the calibrated screw length value for the angle at which the screw 232 is inserted. It is contemplated that in some configurations where calibration is not required or is not performed for a particular screw type or plate, the nominal screw length may still be compensated for the angle at which the screw 232 is inserted.

[0106] Reference Figure 4 , the surgical handpiece assembly 62 includes a sensor 554 configured to generate an orientation signal in response to the orientation of the surgical handpiece assembly 62 and more specifically in response to the orientation of the depth measurement extension 134 and the measurement axis MX along which the depth measurement extension 134 extends. The controller 78 is configured to receive the signal from the sensor 554 and determine the appropriate screw length for bone fixation based on the signal from the sensor 554. The sensor 554 can be an accelerometer, a gyroscope sensor, a stereo sensor, or another sensor configured to generate a signal to the controller 78 in response to the orientation of the surgical handpiece assembly 62. The sensor 554 can be coupled to the module housing 130 to be releasably attached to the handpiece housing assembly 74. Alternatively, in a configuration in which the module housing 130 is integral with the handpiece housing assembly 74, the sensor 554 can be coupled to the handpiece housing assembly 74.

[0107] Reference Fig.19 and Fig. 20 The angle at which the surgical handpiece assembly 62 is drilled can be used to determine the angle at which the screw 232 will be inserted to find the compensation length. The depth measurement extension 134 can be used by the user in the reference orientation 556 (e.g. Fig.19 ) and drilling orientation 558 (as shown Fig. 20266 and the bone plate 234. In the drilling orientation 558, the measuring axis MX of the depth measurement extension 134 is at an angle of inclination relative to the reference axis RX. The angle of inclination is the drilling angle at which the screw 232 will later be inserted.

[0108] The controller 78 can be configured to receive an orientation signal from the sensor 554 corresponding to the depth measurement extension 134 being in the drilling orientation 558. The controller 78 can then be configured to determine a drilling angle of the depth measurement extension 134 based on the orientation signal. The controller 78 can then be configured to determine a compensation length based on the drilling angle. The controller 78 can then use the compensation length to compensate the nominal screw length or the calibration screw length in response to the drilling angle to determine an appropriate screw length for bone fixation.

[0109] like Figure 4 As shown, in a configuration where the sensor 554 includes a gyro sensor 554, the gyro sensor 554 can be coupled to the module housing 130. In other configurations, the gyro sensor 554 is coupled to the nose housing assembly 74. The gyro sensor 554 can generate an orientation signal in response to the angular velocity. The orientation signal can include angular velocity values ​​in at least two directions of the X, Y, and Z directions (see Fig.19 and 20 ), the angular velocity value corresponding to the change in orientation of the depth measurement extension 134 when the depth measurement extension 134 moves from the reference orientation 556 to the drilling orientation 558. The controller 78 can be configured to determine the drilling angle of the depth measurement extension 134 by integrating the angular velocity value over a duration period. The duration period can begin when the reference orientation 556 is established, and the duration period can end when the drilling orientation 558 is established. By integrating the angular velocity value, the controller 78 can then determine the change in orientation of the depth measurement extension 134 from the reference orientation 556 to the drilling orientation 558, and thus the controller 78 can determine the drilling angle between the reference and drilling orientations 556, 558.

[0110] The user can operatively engage the user input of the surgical handpiece system 60 to establish the reference orientation 556 and the drilling orientation 558. Alternatively, the controller 78 can be configured to generate signals in response to certain parameters to establish the reference and drilling orientations 556, 558. Some of these parameters will be discussed below. Establishing the reference and drilling orientations 556, 558 can improve the accuracy of the controller 78 when determining the drilling angle relative to the bone plate 234 based on the careful orientation / manipulation of the surgical handpiece assembly 62 by the user. In other words, when the user operatively engages the surgical handpiece assembly 62 to establish the reference and drilling orientations 556, 558, or when certain parameters are met to establish the reference and drilling orientations 556, 558, the possibility of the controller 78 determining an erroneous drilling angle from the orientation signal generated by the sensor 554 is mitigated.

[0111] As described above, the displacement sensor assembly 136 can be configured to generate a displacement signal to the controller 78 in response to displacement of the drill bit 66 relative to the depth measurement extension 134 during the drilling process or in preparation for the drilling process. One or both of the reference and drilling orientations 556, 558 can be established by the controller 78 (i) receiving the displacement signal, and (ii) determining that the drill bit 66 has been displaced a predetermined distance relative to the depth measurement extension 134.

[0112] Reference Figures 21A-24 , shows one configuration of the surgical handpiece assembly 62 before and during the drilling process. Figures 21A-24 The bone plate 234 is shown disposed on the outer surface of the proximal cortex 550 of the bone 266, but it is contemplated that the drilling angle may be determined when the bone plate 234 is not present. Fig.21A , the surgical handpiece assembly 62 is spaced apart from the bone plate 234 and the depth measurement extension 134 is not yet in the reference orientation 556. Fig.21B (corresponding to Fig.19 ), the depth measurement extension 134 is shown in a reference orientation 556. When the depth measurement extension 134 is Fig.21A Move to the position shown Fig.21B 556, the depth measurement extension 134 is displaced relative to the drill bit 66. The controller 78 can be configured to receive a displacement signal in response to the displacement of the depth measurement extension 134 relative to the drill bit 66 and determine that the depth measurement extension 134 is in a reference orientation 556. Establishing the reference orientation 556 can provide a "zero offset" or baseline from which the drilling angle can be determined. For example, in a configuration including a gyroscopic sensor 554, when the reference orientation 556 is established, the gyroscopic sensor 554 can begin to generate signals corresponding to angular velocity in at least two of the X, Y, and Z directions (see Fig.19 and20 ).

[0113] exist Fig. 22 In the embodiment, the surgical handpiece assembly 62 is in line with the drilling angle (corresponding to Fig. 20 ), however, the drilling orientation 558 of the depth measurement extension 134 may not yet be established. Fig.23 , the depth measurement extension 134 is shown in the drilling orientation 558. Fig. 22 Move to the position shown Fig.23 In the position shown, the depth measurement extension 134 is displaced relative to the drill bit 66. The controller 78 can be configured to receive the displacement signal in response to the displacement of the depth measurement extension 134 relative to the drill bit 66 and determine that the depth measurement extension 134 is in the drilling orientation 558. Fig.23 The drill bit 66 is shown to have been displaced through the proximal cortex 550 in the drilling orientation 558, but it is contemplated that the drill bit 66 may not need to enter such a depth into the bone 266 for the controller 78 to determine that the depth measurement extension 134 is in the drilling orientation 558. Instead, the controller 78 may determine that the depth measurement extension 134 is in the drilling orientation 558 when the displacement of the depth measurement extension 134 relative to the drill bit 66 has exceeded a predetermined displacement (e.g., 5 mm in the bone 266). In a configuration that includes a gyro sensor 554, the gyro sensor 554 may cease to generate a signal corresponding to the angular velocity when the drilling orientation 558 is established. As described above, the controller 78 may then integrate the angular velocity value over a period of time between the time when the reference orientation 556 is established and the time when the drilling orientation 558 is established.

[0114] In another configuration, one or both of the reference and drilling orientations 556, 558 may be established by motor status signals. The surgical handpiece assembly 62 may include another sensor 562 (see Figure 4), which is configured to generate a motor state signal to the controller 78 in response to the state of the motor 84. One or both of the reference and drilling orientations 556, 558 can be established by the controller 78 determining that the state of the motor 84 has changed from an idling state to a running state. In one configuration, the motor state signal corresponds to the torque generated by the motor 84. The motor 84 does not generate torque in the idling state, and the motor 84 generates torque in the running state. In another configuration, the motor state signal corresponds to the speed of the motor 84. The motor 84 operates at a speed below a speed threshold in the idling state, and the motor 84 operates at another speed above the speed threshold in the running state. In one configuration, the sensor 562 can be an accelerometer arranged in the measurement module 128. Alternatively, a single sensor can be used to determine both the angular offset and the motor state.

[0115] In one exemplary configuration, a user may orient the depth measurement extension 134 from a reference orientation 556 to a drilling orientation 558. The drilling orientation 558 may be established when the controller 78 determines from the motor status signal that the motor 84 has changed from an idle state to a running state.

[0116] In another configuration, one or both of the reference and drilling orientations 556, 558 can be established by actuating the trigger 80 (the user input device 80 described above). The trigger 80 can be used to generate a trigger signal to the controller 78 in response to the user's actuation of the trigger 80 to operate the motor 84 to generate torque. One or both of the reference and drilling orientations 556, 558 can be established by the controller 78 determining that the trigger 80 has been actuated. In an exemplary configuration, the user can orient the depth measurement extension 134 from the reference orientation 556 to the drilling orientation 558. When the controller 78 determines from the trigger signal that the trigger 80 has been actuated, the drilling orientation 558 can be established.

[0117] In yet another configuration, one or both of the reference and drilling orientations 556, 558 may be established by a user input device 564. The surgical handpiece assembly 62 may include a user input device 564 separate from the user input device 80 (trigger) for operating the motor 84 described above. The user input device 564 may be coupled to a measurement head, such as Figure 1Module housing 130 shown. Alternatively, a user input device 564 may be alternatively coupled to the nose housing assembly 74. The user input device 564 may be operable to generate a first reference signal to the controller 78 to establish that the measurement axis MX is aligned with the reference axis RX and to determine that the depth measurement extension 134 is in the reference orientation 556. For example, a user may orient the depth measurement extension 134 to the reference orientation 556 and then actuate (e.g., press a button) the user input device 564 to generate a first reference signal to the controller 78. The controller 78 may then determine that the depth measurement extension 134 is in the reference orientation 556. Similarly, the same or another user input device may be actuated again to generate the same or a second reference signal to the controller 78 to establish the drilling orientation 558.

[0118] In another configuration, one or both of the reference and drilling orientations 556, 558 may be established by the controller 78 determining that the orientation signal from the sensor 554 of the depth measurement extension 134 remains substantially constant for a predetermined duration, and thus the depth measurement extension 134 remains stationary. In an exemplary configuration, the user may orient the depth measurement extension 134 from the reference orientation 556 to the drilling orientation 558. The drilling orientation 558 may be established when the controller 78 determines from the orientation signal that the depth measurement extension 134 has remained stationary for more than a predetermined duration. The predetermined duration may vary, but exemplary times are at least 3, 5, or 10 seconds.

[0119] It is contemplated that one or both of the reference and drilling orientations 556, 558 may be established in a manner other than that specified above. It is also contemplated that a combination of the above configurations may be used to establish one or both of the reference and drilling orientations 556, 558. For example, in Fig.21A In the embodiment, the surgical handpiece assembly 62 is spaced apart from the bone plate 234, and the depth measurement extension 134 is not yet in the reference orientation 556. When the user manipulates the surgical handpiece assembly 62 to place the depth measurement extension 134 in the reference orientation 556, the depth measurement extension 134 is not yet in the reference orientation 556. Fig.21B (corresponding to Fig.19 ) After the reference orientation 556 is established, the user can actuate the user input device 564 to generate a reference signal to the controller 78, and the controller 78 can determine that the reference orientation 556 is established. The user can then manipulate the depth measurement extension 134 to Fig. 22 (corresponding to Fig.19 ) and begins drilling through the proximal cortex 550. After the drill bit 66 has exceeded a predetermined displacement relative to the depth measurement extension 134, the controller 78 can determine that the drilling orientation 558 has been established.

[0120] After the controller 78 determines the drilling angle, the controller 78 can determine the compensation length by using a function that depends at least in part on the drilling angle. The function also depends on the nominal screw length or the calibration screw length including the adjustment length. Alternatively, the controller 78 can determine the compensation length by using a lookup table that depends at least in part on the drilling angle. More specifically, the lookup table can associate a specific drilling angle range with a single compensation length. In an exemplary configuration, a drilling angle between 0 (zero) degrees and 10 (ten) degrees can output a compensation length of 0 mm (zero millimeter); a drilling angle greater than or equal to 10 (ten) degrees and less than 45 (forty-five) degrees can output a compensation length of 1 mm (one millimeter); a drilling angle greater than or equal to 45 (forty-five) degrees can output a compensation length of 2 mm (two millimeters). Other ranges of drilling angles and associated compensation lengths can be considered. Alternatively, the controller 78 can determine the compensation length by interpolating between discrete angles using a lookup table. More specifically, the lookup table can associate discrete drilling angle values ​​with compensation lengths so that each drilling angle value listed in the lookup table corresponds to a single compensation length, and if the drilling angle to be queried is between two drilling angle values ​​in the lookup table, the controller 78 can determine the compensation length by interpolating between the compensation lengths corresponding to the above two drilling angle values. For example, the lookup table can provide a compensation length of 1 mm corresponding to a 10 (ten) degree drilling angle and a compensation length of 1.5 mm corresponding to a 30 (thirty) degree drilling angle. When the drilling angle is 20 (twenty) degrees, the controller 78 can determine that the compensation length is 0.25 mm. It is conceivable that the interpolation can be completed using the linear relationship described in the example or another function that depends on the drilling angle. The lookup table may also depend on the nominal screw length or the calibration screw length including the adjustment length. The lookup table and other computer software described herein can be stored in a memory in the measurement module 128, or in a memory associated with a remote device such as a tablet computer that wirelessly communicates with the measurement head.

[0121] After determining the compensation length, the controller 78 can be configured to output an appropriate screw length for bone fixation, which is dependent upon the nominal screw length (determined by the displacement of the depth measurement extension 134 after drilling) and one or both of the compensation length (determined by the drilling angle) and the adjustment length (determined during the calibration process for the specific plate 234 and screw 232 type selected).

[0122] Reference Fig.25 , surgical handpiece system 60 can include a remote device 566 having a display 568. Remote device 566 can be configured to generate signals to and receive signals from surgical handpiece assembly 62. Fig.25The remote device 566 in the surgical handpiece assembly 62 includes a tablet computer. However, it is contemplated that the remote device 566 may alternatively include a smart phone, a laptop computer, a workstation, or a desktop computer. One or both of the display 148 on the surgical handpiece assembly 62 and the display 568 on the remote device 566 may output one or more of the following: appropriate screw length, compensation length, adjustment length, nominal screw length, displacement of the depth measurement extension 134, drilling angle, specific plate 234 used, specific screw 232 type used, and other information related to the surgical handpiece system 60.

[0123] In one configuration, one or both of the surgical handpiece assembly 62 and the remote device 566 include a user input device (not shown) for inputting or selecting information to the controller 78. The user can enter or select a tilt drilling factor in lieu of a compensation length to compensate for the nominal screw length or a calibration screw length including an adjustment length. The controller 78 can be configured to determine the appropriate screw length based on the nominal screw length (determined by the displacement of the depth measurement extension 134 after drilling), the adjustment length (determined during the calibration process for the specific plate 234 and screw 232 type selected), and the user input / selected tilt drilling factor. The appropriate screw length can be output to one or both of the display 148 on the surgical handpiece assembly 62 and the display 568 on the remote device 566.

[0124] It will be further understood that the terms "including" and "comprising" have the same meaning. In addition, it will be appreciated that terms such as "first", "second", "third", etc. are used herein to distinguish certain structural features and components for clear and consistent non-limiting illustrative purposes. In this application, including the following definitions, the term "controller" may be replaced with the term "circuit". The term "controller" may refer to, belong to or include: an application-specific integrated circuit (ASIC); a digital, analog or analog / digital hybrid discrete circuit; a digital, analog or analog / digital hybrid integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated or group) that executes code; a memory circuit (shared, dedicated or group) for storing code executed by the processor circuit; other suitable hardware components that provide the above functions; or a combination of some or all of the above, such as in a system on a chip.

[0125] The controller may include one or more interface circuits. In some examples, the interface circuit may implement a wired or wireless interface connected to a local area network (LAN) or a wireless personal area network (WPAN). Examples of LANs are the Institute of Electrical and Electronics Engineers (IEEE) standard 802.11-2016 (also known as the WIFI wireless network standard) and the IEEE standard 802.3-2015 (also known as the ETHERNET wired network standard). Examples of WPANs are the BLUETOOTH wireless network standard from the Bluetooth Special Interest Group and the IEEE standard 802.15.4.

[0126] The controller may communicate with other controllers using interface circuits. Although the controller may be depicted in the present disclosure as being in logical communication directly with other controllers, in various embodiments, the controller may actually communicate via a communication system. The communication system includes physical and / or virtual network devices, such as hubs, switches, routers, and gateways. In some embodiments, the communication system is connected to or spans a wide area network (WAN) such as the Internet. For example, the communication system may include multiple LANs connected to each other via the Internet or point-to-point leased lines using technologies including multi-protocol label switching (MPLS) and virtual private networks (VPNs).

[0127] In various embodiments, the functionality of a controller may be distributed across multiple controllers connected via a communication system. For example, multiple controllers may implement the same functionality distributed by a load balancing system. In another example, the functionality of a controller may be divided between a server (also referred to as a remote or cloud) controller and a client (or user) controller.

[0128] Some or all of the hardware functions of the controller may be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly referred to as "Verilog") and IEEE Standard 1076-2008 (commonly referred to as "VHDL"). Hardware description languages ​​may be used to manufacture and / or program hardware circuits. In some embodiments, some or all of the features of the controller may be defined by a language such as IEEE 1666-2005 (commonly referred to as "SystemC"), which includes both code and hardware descriptions as described below.

[0129] As used above, the term code may include software, firmware, and / or microcode, and may refer to programs, routines, functions, classes, data structures, and / or objects. The term shared processor circuit includes a single processor circuit that executes some or all code from multiple controllers. The term group processor circuit encompasses a processor circuit that combines with other processor circuits to execute some or all code from one or more controllers. References to multiple processor circuits include multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term shared memory circuit includes a single memory circuit that stores some or all code from multiple controllers. The term group memory circuit includes a memory circuit that combines with other memories to store some or all code from one or more controllers.

[0130] The term memory circuit is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not cover transient electrical or electromagnetic signals propagated through a medium (e.g., on a carrier wave); therefore, the term computer-readable medium may be considered tangible and non-transitory. Non-limiting examples of non-transitory computer-readable media are non-volatile memory circuits (e.g., flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (e.g., static random access memory circuits or dynamic random access memory circuits), magnetic storage media (e.g., analog or digital tapes or hard drives), and optical storage media (e.g., CDs, DVDs, or Blu-ray Discs).

[0131] The apparatus and method described in this application can be partially or completely implemented by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The above-mentioned functional blocks and flow chart elements are used as software specifications, which can be converted into computer programs through routine work of technicians or programmers.

[0132] The computer program includes processor executable instructions stored on at least one non-transitory computer readable medium. The computer program may also include or rely on stored data. The computer program may include a basic input / output system (BIOS) that interacts with the hardware of the special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0133] The computer program may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language) or JSON (JavaScript Object Notation), (ii) assembly code, (iii) object code generated by a compiler from source code; (iv) source code executed by an interpreter; (v) source code compiled and executed by a just-in-time compiler, etc. By way of example only, source code may be written using the syntax of languages ​​including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK, and

[0134] Several configurations have been discussed in the foregoing description. However, the configurations discussed herein are not intended to be exhaustive or to limit the invention to any particular form. The terms used are intended to have the nature of descriptive words, rather than restrictive. In view of the above teachings, many modifications and variations are possible, and the invention may be practiced in a manner different from that specifically described.

[0135] The present invention is intended to be defined in the independent claims, wherein specific features are set out in the dependent claims, wherein the subject matter of a claim dependent on an independent claim can also be implemented in combination with another independent claim.

[0136] The present disclosure also includes the following clauses, wherein specific features are listed in the dependent clauses, which may be specifically implemented as described in more detail with reference to the above configurations and drawings.

[0137] I. A system for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopaedic implant kit, the system comprising:

[0138] The surgical handpiece system includes a depth measurement extension and is configured to determine the thickness of a bone when a drill bit is attached and used to drill through the bone; and

[0139] a calibration fixture configured to engage the depth measurement extension of the surgical handpiece system to determine an adjustment amount of an orthopaedic implant kit, the calibration fixture comprising:

[0140] a housing defining a receiver configured to receive a surgical screw of the orthopaedic implant kit, the housing having a first end configured to approach a distal surface of the surgical handpiece system to axially secure the housing of the calibration fixture relative to the surgical handpiece system; and

[0141] a slider movably coupled to the housing and configured to move axially relative to the housing, wherein the slider has a proximal surface configured to engage the depth measurement extension of the surgical handpiece system and a second surface configured to engage a surgical screw,

[0142] The adjustment amount is determined according to the displacement of the depth measurement extension.

[0143] II. The system of clause I, wherein the surgical handpiece system is releasably coupled to the calibration fixture.

[0144] III. The system of any of clauses I-II, wherein the surgical handpiece system further comprises a measurement module removably coupled to a body of the surgical handpiece system, the measurement module comprising the depth measurement extension.

[0145] IV. The system of clause III, wherein the measurement module includes a display.

[0146] V. The system of any of clauses III-IV, wherein the measurement module includes a memory for storing the adjustment amount.

[0147] VI. The system of any of clauses III-V, wherein the measurement module is configured to output a nominal screw length based on the adjustment amount.

[0148] VII. The system of any of clauses I-VI, wherein the opening to the receiver is located on a distal surface of the housing and is configured to receive a surgical screw of a surgical plate of an orthopaedic implant kit intended for use during a surgical procedure.

[0149] VIII. The system of any of clauses I-VII, wherein the calibration fixture is cylindrical.

[0150] IX. The system of any of clauses I-VIII, wherein the calibration fixture is T-shaped.

[0151] X. The system of clause IV, wherein the measurement module comprises a processor.

[0152] XI. The system of clause X, wherein the surgical handpiece system is configured to operate in multiple modes, including a drilling mode and a calibration mode.

[0153] XII. The system of any of clauses X-XI, wherein the processor is configured to receive a nominal size of the surgical screw from a user and to subtract the displacement value of the depth measurement extension to determine the adjustment amount.

[0154] XIII. The system of any of clauses X-XII, wherein the display is configured to provide the displacement value to a user, and the measurement module includes a user interface configured to receive the adjustment amount from the user.

[0155] XIV. The system of any of clauses I-XIII, wherein the surgical handpiece system comprises a sensor assembly configured to detect the presence of the calibration fixture in a calibration position relative to the surgical handpiece system.

[0156] XV. The system of clause XIV, wherein the sensor comprises a magnetoresistive sensor configured to sense a magnet connected to the housing of the calibration fixture.

[0157] XVI. The system of claim XIV, wherein the sensor assembly comprises a mechanical button, an RFID chip, a key handle, a proximity sensor, or a capacitive sensor and is configured to send and receive signals when the calibration fixture is in a calibration position relative to the surgical head system.

[0158] XVII. The system of any of clauses X-XIII, wherein the processor is configured to output a nominal size of a surgical screw to be used with the calibration fixture.

[0159] XVIII. The system of clause XIV further includes a processor that is either integrated with the surgical head system or integrated with a measurement module that is movably connected to the surgical head system, wherein the processor is configured to receive sensor data from the sensor assembly and automatically enter a calibration mode based on the sensor data.

[0160] XIX. The system of claim X, wherein the processor is further configured to determine the adjustment amount based on a nominal size of the surgical screw, a distance from a distal end of the housing / body of the calibration fixture to a distal end of the surgical head system, a length of the slider, and a displacement of the depth measurement extension.

[0161] XX. The system of any of clauses I-XIX, wherein a receptacle defined by the housing for receiving a surgical screw is offset from the depth measuring extension.

[0162] XXI. A system for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopaedic implant kit, the system comprising:

[0163] The surgical handpiece system includes a depth measurement extension and is configured to determine the thickness of a bone when a drill bit is attached and used to drill through the bone; and

[0164] A calibration fixture configured to engage the depth measurement extension of the surgical handpiece system to determine an adjustment amount of an orthopaedic implant kit, the calibration fixture comprising a housing defining:

[0165] a first receiver offset from the depth measurement extension and configured to receive a surgical screw of the orthopaedic implant kit;

[0166] a proximal side configured to be proximate to a distal surface of the surgical handpiece system to axially secure a housing of the calibration fixture relative to the surgical handpiece system;

[0167] A second receiver is configured such that a distal end of the receiver abuts a distal end of the depth measurement extension, wherein the adjustment amount is based on a displacement of the depth measurement extension.

[0168] XXII. A method for calibrating a surgical handpiece system having a depth measurement extension capable of determining a drilling depth of an orthopaedic implant kit, the method comprising:

[0169] Entering calibration mode of the surgical handpiece system;

[0170] placing a housing of the calibration fixture in abutment with the surgical handpiece system such that a slider inside the housing is adjacent to a depth measurement extension of the surgical handpiece system;

[0171] selecting surgical screws and plates from an orthopedic implant kit to be used in an upcoming surgical procedure;

[0172] inserting a surgical screw through the surgical plate and into a receptacle defined by the housing to move the depth measurement extension relative to the body of the surgical handpiece system;

[0173] Provide the surgical handpiece system with any of the following:

[0174] The nominal size of the surgical screw provided by the manufacturer of the orthopedic implant kit, or the adjustment amount of the surgical screw and plate determined by:

[0175] Output displacement through the surgical handpiece, and

[0176] Subtract the displacement output by the surgical handpiece system from the nominal size of the surgical screw;

[0177] drilling through the bone using the surgical handpiece system and obtaining the thickness of the bone from the displacement of the depth measuring extension; and

[0178] The recommended size of the surgical screw is displayed based on the thickness of the bone and the determined adjustment amount or nominal size of the screw used for calibration.

[0179] XXIII. The method of clause XXII, wherein the recommended size is the nominal screw value that is closest to the sum of the adjustment amount plus the thickness of the bone.

[0180] XXIV. The method of clause XXII, wherein the recommended size of the surgical handpiece system is a nominal screw value that is greater than the sum of the adjustment amount plus the thickness of the bone.

[0181] XXV. A method for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopaedic implant kit, the method comprising:

[0182] Determine the nominal size of the surgical screws by the surgical handpiece system;

[0183] selecting a surgical screw of the determined nominal size from an orthopedic implant kit;

[0184] Selecting a surgical plate from the orthopedic implant kit to be used in the upcoming surgery;

[0185] abutting the housing of the calibration fixture against the surgical handpiece system, thereby inserting the depth measurement extension of the surgical handpiece system into the space defined by the housing of the calibration fixture;

[0186] inserting a surgical screw through the surgical plate and into a second space defined by the housing of the calibration fixture;

[0187] Depress the depth measurement extension of the surgical handpiece system with a calibration fixture or surgical screw;

[0188] sensing, with the surgical handpiece system, the presence of the calibration fixture and entering a calibration mode in response to the sensing;

[0189] The amount of adjustment is determined by measuring the displacement of the extension based on the nominal size of the surgical screw and the depth to which it is depressed;

[0190] Drilling through bone and gaining bone thickness using a surgical handpiece system; and

[0191] The recommended size of the surgical screw is output based on the thickness of the bone and the determined adjustment amount.

[0192] XXVI. The method of claim XXV, wherein determining the adjustment amount is also based on: the distance from the distal end of the calibration fixture to the abutment between the calibration fixture and the surgical head system, the length of the slider mounted in the calibration fixture, and the distance from the abutment to the distal end of the depth measurement extension.

[0193] XXVII. The method of any of clauses XXV-XXVI, wherein outputting a recommended size for the surgical screw is performed only if the determined adjustment amount is less than four millimeters.

[0194] XXVIII. The method of any of clauses XXV-XXVII, wherein the nominal size of the surgical screw is determined to be between 24 mm and 36 mm.

[0195] XXIX. The method of any of clauses XXV-XXVIII, wherein the surgical handpiece system displays a recommended size that is closest to the sum of the adjustment amount plus the thickness of the bone.

[0196] XXX. The method of any of clauses XXV-XXVIII, wherein the surgical handpiece system displays a recommended size that is greater than the sum of the adjustment amount plus the thickness of the bone.

[0197] XXXI. The method of any of clauses XXV-XXX, wherein the sensing step is performed by the surgical handpiece system sensing a magnetic field from a magnet of a calibration fixture.

[0198] XXXII. A method for calibrating a surgical handpiece system capable of determining a drilling depth of an orthopaedic implant kit, the method comprising:

[0199] providing a block having a plate-like surface;

[0200] selecting an orthopedic implant kit for use in a surgical procedure, wherein the orthopedic implant kit includes a depth gauge calibrated to the kit;

[0201] Selecting a surgical plate to be implanted from a plastic surgery implant kit;

[0202] positioning the opening of the surgical plate over the opening of the calibration block and positioning the block so that the block abuts the plate;

[0203] Insert the depth gauge through the openings of the calibration block and plate;

[0204] Subtract the thickness of the block from the value listed on the depth gauge to get the adjustment amount;

[0205] Drilling through bone and gaining bone thickness using a surgical handpiece system; and

[0206] The recommended size of the surgical screw is calculated based on the above bone thickness and the above adjustment amount.

[0207] XXXIII. The method of clause XXXII, further comprising inputting the determined adjustment amount into the surgical handpiece system.

[0208] XXXIV. The method of any of clauses XXXII-XXXIII, further comprising the surgical handpiece system determining a recommended screw size that is the sum of the thickness of the proximal bone plus the adjustment amount.

[0209] XXXV. The method of any of clauses XXXII-XXXIII, further comprising the surgical handpiece system determining a recommended screw that is greater than the sum of the thickness of the bone plus the adjustment amount.

[0210] XXXVI. The method of any of clauses XXXII-XXXIII, further comprising: selecting a surgical screw based on the adjustment amount plus the thickness of the bone and the area of ​​the patient where the screw is to be implanted.

[0211] XXXVII. The method of any of clauses XXXII-XXXIII, further comprising selecting a surgical screw for implantation that is closest in size to the surgical screw.

[0212] XXXVIII. A surgical handpiece system for determining an appropriate screw length for bone fixation in conjunction with a bone plate that compensates for an initial screw length value based on an orientation of the surgical handpiece system during drilling, the surgical handpiece system comprising:

[0213] A surgical handpiece assembly, the surgical handpiece assembly comprising:

[0214] Head shell

[0215] an electric motor disposed within the handpiece housing and configured to generate torque,

[0216] a depth measuring extension movably coupled to the handpiece housing,

[0217] a coupling chuck coupled to the motor and configured to receive torque therefrom, and

[0218] a sensor configured to generate an orientation signal in response to an orientation of the depth measurement extension;

[0219] A controller is configured to receive the signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor.

[0220] XXXIX. The surgical handpiece system of clause XXXVIII, wherein the sensor comprises at least one sensor selected from an accelerometer, a gyro sensor, and a stereo sensor.

[0221] XL. The surgical handpiece system of any of clauses XXXVIII-XXXIX, wherein the depth measurement extension defines a measurement axis, the depth measurement extension being movable by a user between a reference orientation in which the measurement axis is aligned with a reference axis extending through a hole defined by a bone plate, and a drilling orientation in which the measurement axis of the depth measurement extension is at an oblique drilling angle relative to the reference axis, and wherein the controller is configured to:

[0222] (i) receiving an orientation signal from a sensor of the depth measurement extension in a drilling orientation,

[0223] (ii) determining a drilling angle of the depth measurement extension based on an orientation signal from a sensor,

[0224] (iii) determining a compensation length in response to the drilling angle, and

[0225] (iv) Determining an appropriate screw length for bone fixation based on the compensation length.

[0226] XLI. The surgical head system of claim XL, wherein the sensor includes a gyroscope sensor and the orientation signal includes an angular velocity value corresponding to a change in the orientation of the depth measurement extension as the depth measurement extension moves from a reference orientation to a drilling orientation, and wherein the controller is configured to determine a drilling angle of the depth measurement extension by integrating the angular velocity value over a duration period, wherein the duration period begins when the reference orientation is established and ends when the drilling orientation is established.

[0227] XLII. The surgical head system of any of clauses XL-XLI, further comprising a drill bit connected to a coupling chuck and configured to receive torque from a motor through the coupling chuck, wherein the depth measurement extension comprises a displacement sensor configured to generate a displacement signal to a controller in response to displacement of the drill bit during drilling, and wherein at least one of the orientations selected from the reference orientation and the drilling orientation is established by: (i) receiving the displacement signal by the controller, and (ii) determining that the drill bit has been displaced a predetermined distance relative to the depth measurement extension.

[0228] XLIII. The surgical handpiece system of clause XLII, wherein the drill bit includes a drill bit axis and the drill bit axis is aligned with a measurement axis of the depth measurement extension.

[0229] XLIV. The surgical head system of any of clauses XL-XLII, further comprising a sensor configured to generate a motor state signal to a controller in response to a state of the motor, wherein at least one of the orientations selected from a reference orientation and a drilling orientation is established by the processor determining that the state of the motor has changed from an idling state to an operating state.

[0230] XLV. The surgical handpiece system of clause XLIV, wherein the motor state signal comprises a torque generated by the motor, and wherein the motor generates no torque in an idle state and wherein the motor generates torque in an operating state.

[0231] XLVI. The surgical handpiece system of clause XLIV, wherein the motor status signal includes a rotational speed of the motor, and wherein the motor operates at a rotational speed below a rotational speed threshold in an idling state, and wherein the motor operates at a rotational speed above the rotational speed threshold in an operating state.

[0232] XLVII. The surgical handpiece system of any of clauses XL-XLI, wherein at least one of the orientations selected from the reference orientation and the drilling orientation is established by the processor determining that an orientation signal from a sensor of the depth measurement extension remains constant over a predetermined period of time.

[0233] XLVIII. A surgical handpiece system of any of clauses XL-XLI, wherein the surgical handpiece assembly further comprises a user input device operable to generate a first reference signal to a processor for establishing that the measurement axis is aligned with the reference axis and that the depth measurement extension is in the reference orientation.

[0234] XLIX. The surgical head system of clause XLVIII, wherein the drilling orientation is established by operation of a user input device to generate a second reference signal, and wherein the processor (i) receives the second reference signal after receiving the first reference signal, and (ii) determines that the depth measurement extension is in the drilling orientation.

[0235] L. A surgical handpiece system as described in any of clauses XL-XLI, wherein the surgical handpiece assembly further comprises a trigger for generating a trigger signal to a controller in response to actuation of the trigger by a user, for operating a motor to generate torque, and wherein at least one of the orientations selected from a reference orientation and a drilling orientation is established by the processor determining that the trigger has been actuated by the user.

[0236] LI. The surgical handpiece system of any of clauses XL-L, wherein the compensation length is selected using a function that depends on the drilling angle.

[0237] LII. The surgical handpiece system of any of clauses XL-L, wherein the compensation length is selected using a lookup table that is dependent on the drilling angle.

[0238] LIII. A surgical handpiece system for determining an appropriate screw length for bone fixation in conjunction with a bone plate that compensates for an initial screw length value based on an orientation of the surgical handpiece system during drilling, the surgical handpiece system comprising:

[0239] A surgical handpiece assembly, the surgical handpiece assembly comprising:

[0240] Head housing,

[0241] an electric motor disposed within the handpiece housing and configured to generate torque,

[0242] a coupling chuck coupled to the motor and configured to receive torque therefrom, and

[0243] a sensor configured to be coupled to the handpiece housing and configured to generate an orientation signal in response to an orientation of the handpiece housing;

[0244] A controller is configured to receive the signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor.

[0245] LIV. A method of determining an appropriate screw length for bone fixation, the method comprising:

[0246] providing a surgical handpiece assembly having a handpiece housing, a motor, and a depth measurement extension defining a measurement axis, the depth measurement extension of the surgical handpiece assembly being coupled to a drill bit;

[0247] orienting the depth measurement extension to a reference orientation adjacent the bone plate such that the measurement axis is aligned with a reference axis extending through a hole defined by the bone plate;

[0248] operating a user input device coupled to the surgical handpiece assembly to establish alignment of a measurement axis of the depth measurement extension with a reference axis;

[0249] orienting the depth measurement extension into a drilling orientation so that the measurement axis is at an oblique angle to the reference axis;

[0250] The tilt angle is measured at the drilling orientation;

[0251] drilling through the proximal cortex of the bone and toward the distal cortex of the bone with the drill bit;

[0252] determining, by a controller, an appropriate screw length for bone fixation based on the inclination angle measurement of the depth measurement extension; and

[0253] Appropriate screw lengths for bone fixation are shown.

[0254] LV. The method of clause LIV, wherein the drill bit defines a drill bit axis aligned with the measurement axis, the method further comprising determining a displacement of the drill bit based on relative movement between the depth measurement extension and the drill bit.

[0255] LVI. The method of clause LV further includes determining, by a controller, the angle of inclination after the drill bit has been displaced through the proximal cortex to a predetermined depth in the bone.

[0256] LVII. A method for determining an appropriate screw length for bone fixation, the method comprising:

[0257] Providing a surgical handpiece assembly having a handpiece housing, a motor, a depth measurement extension, and a drill bit;

[0258] Drill through the proximal cortex of the bone and toward the distal cortex of the bone;

[0259] measuring the depth of the drill hole in the bone;

[0260] determining an appropriate screw length for bone fixation based on the measured drilling depth and tilt drilling factor; and

[0261] Appropriate screw lengths for bone fixation are shown.

[0262] LVIII. The method of clause LVII, wherein the surgical head assembly further comprises a user input device, the method further comprising operating the user input device to select a tilt drilling factor before the controller determines an appropriate screw length for bone fixation.

[0263] LVIX. The method of any of clauses LVII-LVIII, wherein the depth measurement extension defines a measurement axis and the drill bit defines a drill bit axis aligned with the measurement axis, the method further comprising measuring the drilling depth by determining a displacement of the drill bit relative to the depth measurement extension.

[0264] LX. A measurement module configured to be coupled to a surgical handpiece assembly and configured to engage a calibration fixture to calibrate an orthopaedic implant kit, the measurement module comprising:

[0265] case;

[0266] a depth measurement extension movably coupled to the housing;

[0267] a displacement sensor assembly coupled to the distal portion of the housing and configured to generate a displacement signal in response to movement of the depth measurement extension relative to the housing;

[0268] a presence sensor coupled to the distal portion of the housing and configured to generate a presence signal in response to the presence of the transmitter coupled to the calibration fixture; and

[0269] a controller configured to receive signals from the displacement sensor assembly and the presence sensor;

[0270] wherein the controller is configured to receive a signal from a presence sensor and determine that the calibration fixture is engaging a distal portion of the shell to operate the surgical head system in a calibration mode, whereby a displacement signal received from the displacement sensor assembly when the surgical head system is in the calibration mode is used to determine an adjustment amount of the orthopedic implant kit, and the controller is configured to store this adjustment amount in a memory.

[0271] LXI. A calibration assembly for calibrating a surgical handpiece system having a depth measurement extension to an orthopaedic implant kit, the calibration assembly comprising:

[0272] A shell having a body, the body defining a first opening at a distal end of the body, a second opening at a proximal end of the body, and an inner cavity extending through the body in fluid communication with the first and second openings, wherein the inner cavity is configured to receive a surgical screw of an orthopaedic implant kit through the first opening, and the inner cavity is configured to receive a depth measurement extension of a surgical handpiece system through the first opening and the second opening, and the proximal end of the shell is configured to engage a distal surface of the surgical handpiece system to axially constrain the shell relative to the surgical handpiece system; and

[0273] a slider movably coupled to the housing and configured to move axially relative to the housing at least partially within the lumen, the slider having a proximal surface configured to engage a depth measurement extension of a surgical handpiece system and a distal surface configured to engage a surgical screw, wherein the slider is configured to be displaced within the lumen by the surgical screw when the surgical screw is received within the first opening;

[0274] Wherein, an adjustment amount of the orthopaedic implant kit is determined based on a displacement of the slider.

Claims

1. A surgical handpiece system for determining an appropriate screw length for bone fixation with a bone plate to compensate for an initial screw length value based on the orientation of the surgical handpiece system during drilling, the surgical handpiece system comprising: A surgical handpiece assembly, the surgical handpiece assembly comprising: Head housing, an electric motor disposed within the handpiece housing and configured to generate torque, a depth measurement extension movably coupled to the handpiece housing, and A sensor configured to generate an orientation signal in response to the orientation of the depth measurement extension; a drill configured to be coupled to and receive torque from a motor of the surgical head assembly; and a processor configured to receive the signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor.

2. The surgical handpiece system of claim 1, wherein: The sensor includes at least one sensor selected from an accelerometer, a gyro sensor, and a stereo sensor.

3. The surgical handpiece system of claim 1, wherein: The depth measurement extension defines a measurement axis, the depth measurement extension being movable by a user between a reference orientation in which the measurement axis is aligned with a reference axis extending through a hole defined by a bone plate, and a drilling orientation in which the measurement axis of the depth measurement extension is at an oblique drilling angle relative to the reference axis, and wherein the processor is configured to: (i) receiving an orientation signal from a sensor of the depth measurement extension in a drilling orientation, (ii) determining a drilling angle of the depth measurement extension based on an orientation signal from a sensor, (iii) determining a compensation length in response to the drilling angle, and (iv) Determining an appropriate screw length for bone fixation based on the compensation length.

4. The surgical handpiece system of claim 3, wherein: The sensor includes a gyroscope sensor, and the orientation signal includes an angular velocity value corresponding to a change in the orientation of the depth measurement extension when the depth measurement extension moves from a reference orientation to a drilling orientation, and the processor is configured to determine a drilling angle of the depth measurement extension by integrating the angular velocity value over a duration period, wherein the duration period starts when the reference orientation is established and ends when the drilling orientation is established.

5. The surgical handpiece system of claim 3, wherein: The depth measurement extension includes a displacement sensor configured to generate a displacement signal to a processor in response to displacement of the drill bit during drilling, and wherein at least one of the orientations selected from the reference orientation and the drilling orientation is established by the processor (i) receiving the displacement signal and (ii) determining that the drill bit has been displaced a predetermined distance relative to the depth measurement extension.

6. The surgical handpiece system of claim 3, further comprising a sensor configured to generate a motor state signal to the processor in response to a state of the motor, wherein: At least one of the orientations selected from the reference orientation and the drilling orientation is established by the processor determining that the state of the motor has changed from an idling state to a running state.

7. The surgical handpiece system of claim 6, wherein: The motor state signal includes torque generated by the motor, and the motor does not generate torque in an idling state, and the motor generates torque in a running state.

8. The surgical handpiece system of claim 6, wherein: The motor state signal includes a rotation speed of the motor, and wherein the motor is operated at a rotation speed lower than a rotation speed threshold in an idling state, and wherein the motor is operated at a rotation speed higher than a rotation speed threshold in a running state.

9. The surgical handpiece system of claim 3, wherein: At least one of the orientations selected from the reference orientation and the drilling orientation is established by the processor determining that an orientation signal from a sensor of the depth measurement extension remains constant over a predetermined period of time.

10. The surgical handpiece system of claim 3, wherein: The surgical handpiece assembly also includes a user input device operable to generate a first reference signal to a processor for establishing that the measurement axis is aligned with the reference axis and that the depth measurement extension is in the reference orientation.

11. The surgical handpiece system of claim 10, wherein: The drilling orientation is established by operation of a user input device to generate a second reference signal, and wherein the processor (i) receives the second reference signal after receiving the first reference signal and (ii) determines that the depth measurement extension is in the drilling orientation.

12. The surgical handpiece system of claim 3, wherein: The surgical head assembly also includes a trigger for generating a trigger signal to a processor in response to actuation of the trigger by a user, for operating the motor to generate torque, and at least one of the orientations selected from the reference orientation and the drilling orientation is established by the processor determining that the trigger has been actuated by the user.

13. The surgical handpiece system according to any one of claims 3-12, wherein: The compensation length is selected using a function that is dependent on the drilling angle.

14. The surgical handpiece system according to any one of claims 3-12, wherein: The compensation length is selected using a look-up table that is dependent on the drilling angle.

15. The surgical handpiece system according to any one of claims 3-12, wherein: The drill bit comprises a drill bit axis, and the drill bit axis is aligned with a measuring axis of the depth measurement extension.

16. A surgical handpiece system for determining an appropriate screw length for bone fixation to a bone plate that compensates for an initial screw length value based on an orientation of the surgical handpiece system during drilling, the surgical handpiece system comprising: A surgical handpiece assembly, the surgical handpiece assembly comprising: Head housing, an electric motor disposed within the handpiece housing and configured to generate torque, a depth measuring extension movably coupled to the handpiece housing, a coupling chuck coupled to the motor and configured to receive torque therefrom, and a sensor configured to generate an orientation signal in response to an orientation of the depth measurement extension; A controller is configured to receive the signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor.

17. A surgical handpiece system for determining an appropriate screw length for bone fixation with a bone plate that compensates for an initial screw length value based on an orientation of the surgical handpiece system during drilling, the surgical handpiece system comprising: A surgical handpiece assembly, the surgical handpiece assembly comprising: Head housing, an electric motor disposed within the handpiece housing and configured to generate torque, a coupling chuck coupled to the motor and configured to receive torque therefrom, and a sensor configured to be coupled to the handpiece housing and configured to generate an orientation signal in response to an orientation of the handpiece housing; A controller is configured to receive the signal from the sensor and determine an appropriate screw length for bone fixation based on the signal from the sensor.

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